FORD GALAXY 2006 Service Repair Manual

Glow Plu\b Sys\fem - 2.2L Dura\forq-TDCi
(129kW/175PS) - DW - Glow Plu\b Sys\femS-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
Dia\bnosis and Tes\fin\b
General Equipmen\f
Inspec\fion and Verifica\fion
1. 1.
Verify\fthe\fcustomer\fconcern.\f
2

. 2.
Visu\blly\finspect\ffor\fobvious\fsigns\fof\felectric\bl\fd\bm\bge.\f
V

isual Inspec\fion Char\f
3. 3.
If\f\bn\fobvious\fc\buse\ffor\f\bn\fobserved\for\freported\fconcern\fis\ffound,\fcorrect\fthe\fc\buse\f
(if\fpossible)\fbefore\fproceeding\fto\fthe\fnext\fstep\f
4. 4.
If\fthe\fc\buse\fis\fnot\fvisu\blly\fevident,\fverify\fthe\fsymptom\f\bnd\frefer\fto\fthe\fFord\f
d
i\bgnostic\fequipment\fto\fdi\bgnose\fthe\fsystem.\f
Ford\fdi\bgnostic\fequipment
Electric\bl

Fuse(s)\f\f

Rel\by\f\f

Wiring\fh\brness\f\f

Electric\bl\fconnector(s)\f\f

Glow\fplug(s)\f\f

Glow\fplug\fwire\f\f

Powertr\bin\fcontrol\fmodule\f(PCM)\f
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Glow Plu\b Sys\fem - 2.2L Dura\forq-TDCi
(129kW/175PS) - DW - Glow Plu\bS-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
Removal and Ins\falla\fion
Removal
NO

TE:\fRemov\bl\fsteps\fin\fthis\fprocedure\fm\by\fcont\bin\finst
\bll\btion\fdet\bils.\f
Ins\falla\fion 1. Refer\fto:\f
In
t\bke\fM\bnifold\f(303-01G\fEngine\f-\f2.2L\f
Dur\btorq-TDCi\f(129kW/175PS)\f-\fDW,\fRemov\bl\f
\bnd\fInst\bll\btion).\f
2. \f
3. Torque:\b 8\fNm
\f
1. To\finst\bll,\freverse\fthe\fremov\bl\fprocedure.\f
\f\f
\f\f
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Engine Emi\b\bion Cont\fol - 2.0L Du\fatec-
HE (107kW/145PS) - MI4/2.0L Du\fatec-
HE Flex Fuel (107kW/145PS) - MI4/2.3L
Du\fatec-HE (118kW/160PS) - MI4 -
Engine Emi\b\bion Cont\fol—2.0L Du\fatec-HE
(MI4)
S-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
De\bc\fiption and Ope\fation
\f\f
De\bc\fiption
Exh\bust\fg\bs\frecircul\btion\f(EGR)\fv\blve\fg\bsket\f
EGR\fv\blve\f
The\fEGR\fsystem\f\bllows\f\b\fme\bsured\fqu\bntity\fof\fexh\bust\fg\bs\fto\fbe\fdirected\fb\bck\fto\fthe\f
i n

t\bke\fm\bnifold.\fThe\fexh\bust\fg\bs\fis\fintroduced\fto\fthe\fincoming\fch\brge\f\bir\fin\fthe\fint\bke\f
m\bnifold,\fwhere\fit\fmixes\fwith\fthe\f\bir/fuel\fmixture\f\bnd\flowers\fthe\fpe\bk\fg\bs\ftemper\bture,\f
reducing\fnitrogen\foxide\f(NOx)\fexh\bust\femissions.\fThe\fEGR\fv\blve\fis\felectric\blly\foper\bted\f
\bnd\fis\fcontrolled\fthrough\f\bn\finput\ffrom\fthe\fpowertr\bin\fcontrol\fmodule\f(PCM).\f Item
1
2
\f
Pa\ft Numbe\f -
-
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\f\fDe\bc\fiption
Cr\bnkc\bse\fvent\foil\fsep\br\btor\f
Positive\fcr\bnkc\bse\fventil\btion\f(PCV)\fv\blve\f
\f\f
De\bc\fiption
V\blve\fcover\f
PCV\fhose\f
Air\fcle\bner\f\bssembly\f
Item
1
2
Item 1
2
3
\f
Pa\ft Numbe\f -
-
\f
Pa\ft Numbe\f-
-
-
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Engine Emi\b\bion Cont\fol - 2.0L Du\fatec-
HE (107kW/145PS) - MI4/2.0L Du\fatec-
HE Flex Fuel (107kW/145PS) - MI4/2.3L
Du\fatec-HE (118kW/160PS) - MI4 -
Engine Emi\b\bion Cont\fol—2.3L Du\fatec-HE
(MI4)
S-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
De\bc\fiption and Ope\fation
\f\f
De\bc\fiption
Exh\bust\fg\bs\frecircul\btion\f(EGR)\fv\blve\fg\bsket\f
EGR\fv\blve\f
The\fEGR\fsystem\f\bllows\f\b\fme\bsured\fqu\bntity\fof\fexh\bust\fg\bs\fto\fbe\fdirected\fb\bck\fto\fthe\f
i n

t\bke\fm\bnifold.\fThe\fexh\bust\fg\bs\fis\fintroduced\fto\fthe\fincoming\fch\brge\f\bir\fin\fthe\fint\bke\f
m\bnifold,\fwhere\fit\fmixes\fwith\fthe\f\bir/fuel\fmixture\f\bnd\flowers\fthe\fpe\bk\fg\bs\ftemper\bture,\f
reducing\fnitrogen\foxide\f(NOx)\fexh\bust\femissions.\fThe\fEGR\fv\blve\fis\felectric\blly\foper\bted\f
\bnd\fis\fcontrolled\fthrough\f\bn\finput\ffrom\fthe\fpowertr\bin\fcontrol\fmodule\f(PCM).\f Item
1
2
\f
Pa\ft Numbe\f -
-
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\f\fDe\bc\fiption
Cr\bnkc\bse\fvent\foil\fsep\br\btor\f
Positive\fcr\bnkc\bse\fventil\btion\f(PCV)\fv\blve\f
PCV\fhose\f
Int\bke\fm\bnifold\f
\f\f
De\bc\fiption
V\blve\fcover\f
PCV\fhose\f
Air\fcle\bner\f\bssembly\f
Item
1
2
3
4
Item 1
2
3
\f
Pa\ft Numbe\f -
-
-
-
\f
Pa\ft Numbe\f-
-
-
Стр. 2 из 2
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Engine Emi\b\bion Cont\fol - 2.0L Du\fatec-
HE (107kW/145PS) - MI4/2.0L Du\fatec-
HE Flex Fuel (107kW/145PS) - MI4/2.3L
Du\fatec-HE (118kW/160PS) - MI4 -
Engine Emi\b\bion Cont\fol
S-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
Diagno\bi\b and Te\bting
Gene\fal Equipment
In\bpection and Ve\fification
1. 1.
Verify\fthe\fcustomer\fconcern.\f
2

. 2.
Visu\blly\finspect\ffor\fobvious\fsigns\fof\fmech\bnic\bl\for\felectric\bl\fd\bm\bge.\f
V

i\bual In\bpection Cha\ft
3. 3.
If\f\bn\fobvious\fc\buse\ffor\f\bn\fobserved\for\freported\fconcern\fis\ffound,\fcorrect\fthe\fc\buse\f
(if\fpossible)\fbefore\fproceeding\fto\fthe\fnext\fstep.\f
4. 4.
If\fthe\fconcern\fis\fnot\fvisu\blly\fevident,\fverify\fthe\fsymptom\f\bnd\frefer\fto\fthe\f
S
ymptom\fCh\brt.\f
Symptom Cha\ft
Worldwide\fDi\bgnostic\fSystem\f(WDS)
Mechanica\bE\bectrica\b

Hose(s)/hose\fjoints\f\f

G\bsket(s)\f\f

Positive\fcr\bnkc\bse\fventil\btion\f(PCV)\fv\blve\f\f

PCV\fsep\br\btor\f\f

Exh\bust\fg\bs\frecircul\btion\f(EGR)\fv\blve\f
Electric\bl\fconnector(s)\f\f

Wiring\fh\brness\f\f

Fuse(s)\f\f

Rel\by\f\f

EGR\fv\blve\f\f

Powert\bin\fcontrol\fmodule\f(PCM)\f
\fymptomPossib\be \fourcesAction
Poor\fengine\f
perform\bnceEGR\fv\blve.\f
*Using\fthe\fWDS,\fCHECK\fthe\fEGR\fV\blve\fDuty\fCycle\finput\f
sign\bl\fto\fthe\fEGR\fv\bcuum\fregul\btor\fv\blve.\fIf\fthe\fresult\fis\f
0%,\fREMOVE\fthe\fEGR\fv\blve.\f\f
REFER\fto:\f Exh\bust\fG\bs\fRecircul\btion\f(EGR)\fV\blve \f(303-
08A

\fEngine\fEmission\fControl\f-\f2.0L\fDur\btec-HE\f
(107kW/145PS)\f-\fMI4/2.0L\fDur\btec-HE\fFlex\fFuel\f
(107kW/145PS)\f-\fMI4/2.3L\fDur\btec-HE\f(118kW/160PS)\f-\f
MI4,\fRemov\bl\f\bnd\fInst\bll\btion).\f
INSPECT\fthe\fEGR\fv\blve\f\bnd\fv\blve\fse\bt\ffor\fd\bm\bge.\fM\bke\f
sure\fth\bt\fthe\fEGR\fv\blve\fis\fin\fthe\fclosed\fposition.\fIf\fthe\f
EGR\fv\blve\fis\fnot\fclosed.\fINSTALL\f\b\fnew\fEGR\fv\blve.\fTEST\f
the\fsystem\ffor\fnorm\bl\foper\btion.\fIf\fthe\fresult\fis\fnot\f0%\f
continue\fthe\fengine\fdi\bgnostic\fusing\fthe\fWDS.\f
*
Excessive\f
cr\bnkc\bse\f
pressureBlocked\for\f
d\bm\bged\fPCV\f
hose(s).\f Blocked\f
cr\bnkc\bse\fvent\f
oil\fsep\br\btor.\f
*
*CHECK\fthe\fPCV\fsystem\fcomponents\ffor\fblock\bges,\fCLEAN\f
or\fINSTALL\fnew\fcomponents\f\bs\fnecess\bry.\f
*
Worn\for\f
d\bm\bged\f
engine\f
components.\f
*REFER\fto:\fEngine\f(303-01A,\fDi\bgnosis\f\bnd\fTesting).\f
*
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Engine Emi\b\bion Cont\fol - 2.0L Du\fatec-
HE (107kW/145PS) - MI4/2.0L Du\fatec-
HE Flex Fuel (107kW/145PS) - MI4/2.3L
Du\fatec-HE (118kW/160PS) - MI4 -
Exhau\bt Ga\b Reci\fculation (EGR) Valve
S-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
Removal and In\btallation
Gene\fal Equipment
Removal
NO

TE:\fRemov\bl\fsteps\fin\fthis\fprocedure\fm\by\fcont\bin\finst
\bll\btion\fdet\bils.\f
In\btallation
Hose\fcl\bmp\fremover/inst\bller 1. Dr\bin\fthe\fcooling\fsystem.\fRefer\fto:\f Cooling\fSystem\fDr\bining,\fFilling\f\bnd\f
Bl e

eding \f(303-03A\fEngine\fCooling\f-\f2.0L\f
Dur

\btec-HE\f(107kW/145PS)\f-\fMI4/2.0L\fDur\btec-
HE\fFlex\fFuel\f(107kW/145PS)\f-\fMI4/2.3L\fDur\btec-
HE\f(118kW/160PS)\f-\fMI4,\fGener\bl\fProcedures).\f
2. \f
3. \f
4. NOTE:\fThe\fg\bsket\fis\fto\fbe\freused\funless\f
d
\b

m\bged.\f
General \bqui\fment: Ho
se\fcl\bmp\f
rem
over/inst\bller \f
Tor

que: 25\fNm
\f
1. CAUTION:\fM\bke\fsure\fth\bt\fthe\fm\bting\f
f \b

ces\f\bre\fcle\bn\f\bnd\ffree\fof\fforeign\fm\bteri\bl.\f
To\finst\bll,\freverse\fthe\fremov\bl\fprocedure.\f
\f\f
\f\f
\f\f
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Engine Emi\b\bion Cont\fol - 2.5L Du\fatec
(162kW/220PS) - VI5 - Engine Emi\b\bion
Cont\fol
S-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
De\bc\fiption and Ope\fation
2.5L Du\fatec-ST (VI5)
Engine Emi\b\bion Component\b
\f\f
De\bc\fiption
Int\bke\fm\bnifold\fto\fturboch\brger\fbre\bther\fhose\f
Cr\bnkc\bse\fvent\foil\fsep\br\btor\fto\fv\blve\fcover\fhose\f
Cr\bnkc\bse\fvent\foil\fsep\br\btor\fto\fint\bke\fm\bnifold\fhose\f
Cr\bnkc\bse\fvent\foil\fsep\br\btor\f
Item
1
2
3
4
\f
Pa\ft Numbe\f -
-
-
-
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Engine Emi\b\bion Cont\fol - 2.5L Du\fatec
(162kW/220PS) - VI5 - Engine Emi\b\bion
Cont\fol
S-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
Diagno\bi\b and Te\bting
In\bpection and Ve\fification
1. 1.
Verify\fthe\fcustomer\fconcern.\f
2

. 2.
Visu\blly\finspect\ffor\fobvious\fsigns\fof\fmech\bnic\bl\fd\bm\bge.\f
V

i\bual In\bpection Cha\ft
3. 3.
If\f\bn\fobvious\fc\buse\ffor\f\bn\fobserved\for\freported\fconcern\fis\ffound,\fcorrect\fthe\fc\buse\f
(if\fpossible)\fbefore\fproceeding\fto\fthe\fnext\fstep.\f
4. 4.
If\fthe\fc\buse\fis\fnot\fvisu\blly\fevident,\fverify\fthe\fsymptom\f\bnd\frefer\fto\fthe\fSymptom\f
C
h\brt.\f
Symptom Cha\ft
Mechanica\bE\bectrica\b

Hose(s)/hose\fjoints\f\f

G\bsket(s)\f\f

Positive\fcr\bnkc\bse\fventil\btion\f(PCV)\fv\blve\f\f

PCV\fcr\bnkc\bse\fvent\foil\fsep\br\btor\f\f

Turboch\brger\f
Electric\bl\fconnector(s)\f\f

Wiring\fh\brness\f\f

Fuse(s)\f\f

Rel\by\f\f

Powert\bin\fcontrol\fmodule\f(PCM)\f
\fymptomPossib\be \fourcesAction
Excessive\f
cr\bnkc\bse\f
pressureBlocked\fPCV\fcr\bnkc\bse\f
vent\foil\fsep\br\btor.\f
Blocked\fPCV\fhose.\f
*
*CLEAN\for\fINSTALL\fnew\fPCV\fcomponents\f\bs\f
necess\bry.\fTEST\fthe\fsystem\ffor\fnorm\bl\f
oper\btion.\f
*
Worn\for\fd\bm\bged\f
engine\fcomponents.\f
*REFER\fto:\fEngine\f(303-01B,\fDi\bgnosis\f\bnd\f
Testing).\f
*
Oil\fin\fthe\f\bir\f
int\bke\fsystemCr\bnkc\bse\fvent\foil\f
sep\br\btor.\f
*CLEAN\for\fINSTALL\f\b\fnew\fcr\bnkc\bse\fvent\foil\f
sep\br\btor.\fTEST\fthe\fsystem\ffor\fnorm\bl\f
oper\btion.\f
*
Turboch\brger\f
*REFER\fto:\fTurboch\brger\f(303-04E,\fDi\bgnosis\f
\bnd\fTesting).\f
*
Worn\for\fd\bm\bged\f
engine\fcomponents.\f
*REFER\fto:\fEngine\f(303-01B,\fDi\bgnosis\f\bnd\f
Testing).\f
*
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